Coal combustion residuals (CCR) are generated during the power generation process and can include fly ash, bottom ash, boilerslag, and flue gas desulfurization (FGD) residuals. CCRs contain trace concentrations of heavy metals and therefore cannot be dumped or stored where rainwater can leach the metals. Liner systems can be used to contain the coal combustion by-products and protect them from leaching into the environment.

Combustion efficiency is of major importance on small boiler plants and the best way to monitor this is by monitoring CO2 emissions. CODEL offer theModel 1010 Cross-Duct CO monitor. Using Infra-red Gas Filter Correlation technology to filter out interferences such as dust and other gases. TheModel 1010has low maintenance requirements and meets the needs of most boiler applications. In addition to small boilers theModel 1010is also used on Animal carcass incinerators and Crematoriums.

In recent years the number of Selective Catalytic Reduction (SCR) and Selective Non-Catalytic Reduction (SNCR) plants for De-NOx have increased significantly. Continuous analysis of NOx prior to the de-NOx plant is often required to measure the concentration generated by the combustion process. This may be required to provide feed-forward to the Ammonia/Urea injection system and also to allow the effectiveness of the reduction process to be assessed. Continuous analysis of NOx post-reduction is required to allow the effectiveness of the reduction process to be assessed. It may also be beneficial to monitor NH3 slippage at this stage by calculating from the pre and post NOx levels if excess Ammonia/Urea is being applied.

Power Generation Combustion Air Measurements: The need for accurate, repeatable & reliable combustion air measurements in power generation plants is critical to efficient operation and safety throughout the entire facility and processes. Coal-fired power plant applications pose a number of challenges to obtaining these critical flow measurements includ¬ing large ducts, limited metering runs, poor velocity and temperature profiles, high vibration, temperatures up to 750° F and dirty `Fly Ash` laden air.

Most large coal fired power plants and combustion processes are required to monitor CO, NO and NO2 (NOx), SO2 and possibly CO2; in addition the analyser has to be normalised to Standard conditions. For this application CODEL offers the five channelGCEM 40 serieswhich uses Infrared absorption to measure these gases plus moisture, pressure and temperature. The analyser can be configured for single channel operation to monitor any of these gases plus CH4 and HCl.

For large combustion plants and power plants we offer theDCEM 2100 particulate monitor. This monitor is certified to EN 15267 part 3 QAL 1 for all industrial processes including waste incineration. It offers outputs in Transmission, Opacity and mg/m3(when calibrated against a Standard Reference Method). TheDCEM 2100offers real-time zero and span calibration and an efficient air purge system to prevent optical contamination.

Many large combustion plants are now required to monitor mass emissions of major pollutants and to do so requires an accurate measurement of stack gas velocity. The VCEM 5100 is certified to EN 15267 part 3 QAL 1 for all industrial processes including waste incineration. It has several key advantages, firstly the sensors optics are not in contact with the hot and dusty environment, the VCEM 5100 can monitor gases at temperatures exceeding 10000C and the analyser requires minimal maintenance. The VCEM 5100 can be used in extremely dust environments such as SCR’s when dust loadings exceed 10g/m3. The VCEM 5100 is in full compliance with EN/ISO 16911 part 2.

Our shredding systems generate granulate from the hardest rubber and old tyre applications for your recycling plant. Regardless of whether you want to use the granulate for pyrolysis, hydrolysis or combustion, we will customize it to exactly fit your needs. Regardless of whether rubber accumulates in the form of tyres, conveyor belts, rubberised chains or as production waste, recycling is economically efficient and makes sense from an environmental perspective. Very powerful shredders are required to recover recyclable materials from rubber waste and old tyres. Our proven and reliable 4-shaft technology is particularly suited in this regard. This system economically performs the pre- and re-shredding in just one step.

Whether combustion, waste incineration or power plant, most of the hot processes call for a measurement of the exhaust gas direct at the source by national laws and international standards. No matter where and at what concentrations nitrogen oxides have to be detected, you can depend on ECO PHYSICS analyzers to handle the job quickly, reliably and with a precision that is unmatched anywhere in the world. Whether at trace levels in a clean room environment or for the analysis of exhaust gases directly at the source, you will find the type of chemiluminescence detector (CLD) to perfectly suit you at ECO PHYSICS.

Our shredding solutions enable you to optimally recycle waste into substitute fuels / alternative fuels and ensure high quality by producing a homogeneous granulate free of foreign objects. The goal of recycling is to use the valuable energy contained in the waste and to substitute the use of fossil fuels. During the recycling process the portions with a high calorific value are separated from the commercial and industrial waste and turned into a marketable product. Depending on the calorific value and the granular size, these fuels are used in fluidised bed combustion, cement plants and substitute fuel power plants.

Procal supply analysers to monitor many different applications from small combustion plants to large power stations. Examples include University Boiler Plants, Carbon Black Plants, Thermal Oxidisers and Community Heating Projects.

Hydrocarbons are a family of organic chemicals consisting of carbon and hydrogen atoms arranged in a variety of ways. Hydrocarbons are found naturally in crude oil and are released into the environment with its combustion (power plants, home heaters etc).

Flammable & combustible liquids are found in virtually every industrial plant. The quantities of these can vary from a few ounces in aerosol cans to several thousand gallons in bulk storage tanks. The principal hazard associated with storage is the accidental discharge or release of the flammable or combustible material into the surrounding area.

The act of capturing and storing CO2 produced from large scale combustion plants such as power stations is becoming more and more favourable and feasible. One of the most common post-combustion CO2 capture methods is by absorption. The absorption plant can be added on to the existing combustion process, with the flue gas first passing through an absorption column where the CO2 reacts with an absorber.

BS EN 14181 is a quality assurance standard relevant to plants operating under the Large Combustion Plant (LCPD) and Waste Incineration (WID) Directives. Quality Assurance Level 2 (QAL2) of this standard involves the parallel testing of the plant automated measurement systems (AMS) against a certified test house, making measurements with a comparative standard.

GasFinder2 can be permanently installed to monitor chemical and petroleum plants for both combustible and toxic gases. GasFinder2 can be used to replace arrays of point sensors for perimeter monitoring. A single light path will replace many point sensors. With GasFinder2 perimeter monitoring, all gas dispersed from a facility is detected and logged.

The combustion properties of fuels are key to the efficient and safe operation of engines used in machinery and plant. One important way to measure the combustion properties of a fuel is by its hydrogen content. The measurement of hydrogen content is widely used for the characterisation of aviation fuel but with the increasing costs of all fuels and the greater incentives for fuel adulteration, this test is increasingly being adopted for non-aviation applications. Our benchtop NMR analyser MQC-23 system is widely used for the measurement of hydrogen in fuels in accordance with ASTM D7171-05.

Catalyst monitoring services use periodic performance testing and lab analysis to track the condition of newly installed catalyst. The goal is to extend the life of the catalyst and it begins by establishing a relationship between operating hours and the catalyst’s condition and performance. Testing and analytical services reveal any decline in performance, direct catalyst maintenance services such as chemical washing, and provide a basis for estimating catalyst life. The scope of catalyst monitoring is scaled to the size of the installation – from a single reciprocating engine with one catalyst element, all the way up to a plant with multiple combustion turbines each having hundreds of catalyst elements. For more visit: www.emerachem.com/catalystmonitoring

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